Fork Seal Tool

I'm about to set new seals in my forks for the '00.

It looks like 1.5" ID Sched 40 PVC will do the trick.

What are you guys using?

How long should I make the pipe? Any special prep to the pipe? (round off edges, clean it, etc)

Thanks

-travis

Along with this...where all can seals be purchased? What is needed besides the upper seal and wiper? How much fluid do they actually hold?

For some reason I don't think the 1 1/2 sched 40 pipe will work....but I forgot why I determined this 3 years ago when I was doing my RaceTech internals. Seems the diameter just wasn't quite right....dunno.

Anyway, I did something similar using a 1 1/2 fitting that had a flange on it for tapping with a hammer. The prep was to:
1. Cut it lengthwise, cuz you don't really need 360 degrees of pipe to tap a seal in place. 180 is fine.
2. Put it on the tube, crank it down tight to the tube with radiator-type stainless hose clamps and hit it hard with a heat gun. Once it cools it will be at the perfect diameter. In my case, it ended up being about 185 degrees of circumference after heat-forming process, so it kinda pops onto the tube and stays there, as you can see in the bottom picture. This was an unintended benefit from the heating/forming work, but it proved to be handy, cuz it just stays put while you're working!

With it popped on to the tube, I used a brass hammer and lightly slid it along the fork tube to whack the "seal tool", thus preventing me from whacking the tube at an angle that could have caused damage.

And...as you can see....it was specially designed for a Y2K bike! :fing02:

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In this shot, you can see the hash marks from the hose clamp at the smaller diameter end.
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It's popped on to the fork tube and stays there by itself.
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Oh wait...I guess it will work on an RC51, too!!

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Make sure you do a nice job taking the burrs off. If one comes off, it can get stuck in your seal and ruin it from the start. Make it long enough to hold in your fist, and personally I would make 2 halves so you can hold both in your fist and bang the seal in by hand.

I use a Motion Pro seal driver. :fing02: Meant for my 43mm vtec forks, but, I found that putting a layer of paper shop towel between it and the fork tube works out well for 41mm tubes also.

Well, if my 1.5" sched 40 pipe doesn't work, I'm certain I have fittings kicking around.

I'm just not "tool wealthy" like Seb (yet http://www.vfrdiscus...tyle_emoticons/default/wink.gif )

Thanks for the idea Trace!

I made mine out of PVC, but can't remember the size either. A standard pipe did not work though. I think it was about 1.5", but then I put an adapter 4-way on it which goes on the oustide of the pipe. This made it bigger and fit the seal better. I also made it long enough to go over the tube and put a cap on it so I can tap it with a hammer and not worry about chipping the PVC. I'll try to remember to take some pictures tonight.

Along with this...where all can seals be purchased? What is needed besides the upper seal and wiper? How much fluid do they actually hold?

Judging by the sludge that came out of my forks, not much. I have 2 quarts ready and waiting. Someone suggested 3.

I got my seals at Service Honda.

Here's what I ordered:
PRODUCT INFORMATION:
Mfg Product Number: 51414-KCR-003
Description: BUSH, GUIDE for 2000 Honda VFR800FI
Order Quantity: 2
Unit Price: $8.11
Total Cost: $16.22

Mfg Product Number: 51415-KCR-003
Description: BUSH, SLIDER for 2000 Honda VFR800FI
Order Quantity: 2
Unit Price: $6.69
Total Cost: $13.38

Mfg Product Number: 51490-MN8-305
Description: SEAL SET, FR. FORK for 2000 Honda VFR800FI
Order Quantity: 2
Unit Price: $18.50
Total Cost: $37.00

Mfg Product Number: 90544-283-000
Description: WASHER (8MM) for 2000 Honda VFR800FI
Order Quantity: 2
Unit Price: $1.56
Total Cost: $3.12

Mfg Product Number: 94109-12000
Description: WASHER, DRAIN (12MM) for Honda
Order Quantity: 5
Unit Price: $0.41
Total Cost: $2.05


Note, the drain washers are for the motor oil :fing02:


And from Sonic Springs:
Products
------------------------------------------------------
1 x VFR800 98-01 - 0.90kg/mm Sonic Springs (25S-090) = $79.95
2 x PJ-1 10w Fork Oil, 1 pint (Most bikes will need 2 pints) (PJ-10) = $15.90
------------------------------------------------------
Sub-Total: $95.85
Zone Rates (Shipping to US : 3 lb(s)): $12.00
Total: $107.85

OH NO! I'M NOT USING HONDA BRAND FORK OIL!!! http://www.vfrdiscus...tyle_emoticons/default/smile.gif

The 5th gen forks can be done with 1 quart of fork oil. I've done it several times and always have a little left.........come to think of it, I have RaceTech springs in there and go off their specs though, not the Honda book. When I had my Superhawk, I did those with one quart and had a little left too (with RaceTech springs).

If you buy the Honda packaged fork oil, you will require 2 of them (I think) because they are not quart size (maybe pint instead??). Don't really know, I usually just buy a quart of Bel-Ray 7wt.

Thanks for the info....not looking forward to this one! I was planning to do this at the tech day in May for us DFW folks...better make sure I have everything I need...I gotta ride it there and home!

Not sure if it helps with the VFR but I used a + fitting for installing seals, gives you a little more hammer area to tap it down. :blink:










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